Wide-range Speed Control for Diaphragm Metering Pumps: LEWA ecodos sequence with new motor

In many applications, metering components in the pharmaceutical or meals trade for example, pumps are required that not solely could be exactly controlled by way of flow rate and dosing time, but also convey the ingredients particularly gently. To enable the proven pump items of the ecodos collection from LEWA GmbH to satisfy this demanding process with much more flexibility and vitality efficiency in the future, the producer is expanding the portfolio to incorporate a new type of wide-range velocity management. Alongside asynchronous motors and servomotors, permanent magnet synchronous motors, or PMSMs for brief, are also used now. They are characterized by high energy efficiency and a control vary greater than 1:200. This considerably expands the range of purposes. With PMSMs, it is not necessary to use a quantity of pumps for various move charges or oversize asynchronous motors for low speeds. Since PMSMs may be designed and not using a fan, they remain compact and easy to scrub. The latter function predestines them for hygienic purposes. High effectivity ranking over the entire control range in accordance with energy effectivity class IE5+ additionally reduces energy prices, thus guaranteeing a decrease total cost of possession (TCO).
The diaphragm metering pumps within the LEWA ecodos series are significantly nicely suited for functions within the food or pharmaceutical industries. All supplies in contact with the fluids used in the pump units meet the FDA and USP Class VI requirements, and the EU directives for the meals business. In the hygienic model, for instance, the pump head is made of PP or electropolished stainless-steel with a floor roughness < 0.5 µm. This facilitates cleansing of the surfaces involved with the product.
The motor applied sciences used so far have needed to make sacrifices: “For traditional asynchronous motors whose rotor is a squirrel-cage rotor, the control range stays restricted to 1:10 (1:50 is possible in individual cases). With encoder feedback, important expansion is feasible,” stated Maurice Wirkner, an application manager at LEWA. “In addition, the drive is relatively inefficient exterior the rated pace range – particularly at low speeds. This requires the drive to be oversized, which will increase operating prices.” Servomotors are optimized for extremely dynamic requirements and also cowl the entire management vary (1-210 pump strokes), however, they’re costlier to buy and in addition, require a servo inverter for control.
Wide-range velocity control with everlasting magnet synchronous motor extends the vary of functions
LEWA has now expanded its own portfolio with a drive expertise that does not have these weaknesses. “Unlike the asynchronous motor, the rotor of this drive consists of everlasting magnets and rotates synchronously, i.e. with out load-dependent slip,” Wirkner explained. “Among other things, it options an excessive management range, which regularly makes the use of multiple pumps for different circulate charges unnecessary.” Particularly within the case of multiple pumps, an extra guide stroke adjustment or electrical stroke adjustment may be dispensed with and the required circulate fee could be realized by pace control only. The PMSM also has a relentless torque. The complete torque may be applied from engine speed zero rpm (standstill) up to the rated velocity of the motor. This ensures particularly smooth and mild system start-up, since every process can be started with a pump capability of 1 p.c as a substitute of the identical old 10 p.c.
It additionally features a high short-term overload capability, which permits a drive design with out oversizing for the starting torque. As a result, smaller, more cost-efficient sizes can be realized than with classic drives. “Like the asynchronous motor, the PMSM may be controlled via a regular frequency converter, so users can depend on widespread elements,” Wirkner explained. “With the servomotor on the contrary, it would be necessary to buy costly servo controllers.” The compact drive may be simply cleaned due to its fanless design and presents excessive IP protection. If required a further conversion process – referred to as nsd tupH – could be applied to the aluminum body for FDA requirements. This makes the floor extraordinarily resistant and even simpler to clean – best for functions with stringent hygienic necessities, such as aroma metering in the food industry or additive dosing within the pharmaceutical trade.
IE5+ PMSM permits value reduction and decentralized options
The sole limitation of the presently used PMSM is that it is only obtainable for secure areas. “Thanks to wide-range pace management with IE5+ PMSM, we will meet the growing buyer demands for a wider adjustment vary and decrease power consumption, as well as general costs,” mentioned Wirkner to sum up the scenario. “ Private of energy efficiency specifically is changing into more and more necessary for our prospects. A decentralized resolution in which the frequency converter is installed immediately on the PMSM, can now be applied with Getriebebau NORD GmbH & Co. KG, LEWA’s motor associate for PMSM, too.”
LEWA GmbH was founded in 1952 by Herbert Ott and Rudolf Schestag as a family enterprise and is today the world’s main producer of metering pumps and course of diaphragm pumps in addition to full metering packages for process engineering. Headquartered in Leonberg, the company developed into a world group in just a few a long time. Since 2022, the corporate has been a part of the Atlas Copco Group, a globally main Swedish manufacturer of compressors, vacuum options, generators, pumps, power tools and meeting systems. Together with the model new owner, LEWA will further broaden the economic pumps enterprise. As a research and manufacturing company, LEWA develops technologies and provides options for the vast array of purposes among its customers. Its products are used primarily in the chemical industry, the cosmetics industry, prescribed drugs and biotechnology, meals and beverage business and power utilities in addition to within the production of plastics, detergents and cleaners. Additional software areas embrace refineries and petrochemicals, the oil and fuel industry, and gas odorization. LEWA presently employs around 1,200 folks and owns 14 subsidiaries around the world alongside having 80 representatives and sales offices in additional than eighty international locations.
Image material:
Image ID: LEWA ecodos LED3 WBR.jpg
Caption: LEWA ecodos LED3 with PMSM
Source: LEWA GmbH
Image ID: ecodos_NORD-IE5plus_opt.jpg
Caption: The PMSMs newly added to the portfolio feature a control vary of 1:200, enabling a wider range of applications to be coated by the same drive or pump.
Source: LEWA GmbH
Image ID: Baby meals.jpg
Caption: The PMSM also has a relentless torque, i.e. all the torque could be referred to as up at speed 0 rpm. This ensures notably clean and gentle system start-up, since every process may be started with a conveyance fee of 1 percent instead of the same old 10 %. (Example: Metering omega 3 fatty acids in the production of child food)
Source: Adobe Stock
Image ID: Torque.jpg
Caption: In distinction to the ASMs proven, the constant torque of the PMSM permits continuous operation at low speeds. Oversizing for the required pump beginning torque has turn out to be unnecessary as a result of excessive overload functionality of the PMSM.
Source: LEWA GmbH
Image ID: Baugrößen_530PWebJPG.jpg
Caption: Like the asynchronous motor, the PMSM may be controlled via a normal frequency converter (NORD, Danfoss, and so forth.) with special parameterization, in order that users can depend on widespread components.
Source: Getriebebau NORD GmbH & Co. KG
Image ID: NORDAC ON Wandmontage BG2_806x502Web.jpg / Nordac ON+ with frequency converter on an IE5 PMSM.jpg
Caption: Decentralized solutions in which the frequency converter is put in directly on the PMSM are also already possible with the PMSMs chosen by LEWA.
Source: Getriebebau NORD GmbH & Co. KG
Image ID: Functional testing.jpg
Caption: As early as 2020, LEWA carried out initial practical testing with the NORD PMSM prototype and an ecodos pump on the pump take a look at bench. In the decrease pace range above all, the PMSM successfully demonstrated the advantages of constant torque: the ecodos test pump could be pushed in a range of 1:480 up to 5 bar.
Source: LEWA GmbH
More data for readers/viewers/interested events:
Ulmer Straße 10, 71229 Leonberg, Germany
Phone: +49 7152 14-0, Fax: +49 7152 14-1303
Email: lewa@lewa.de
Internet: www.lewa.de
More data for members of the press
ABOPR Pressedienst B.V.
Stefan-George-Ring 19, 81929 Munich, Germany
Phone: +49 89 500315-20, Fax: +49 89 500315-15
Email: info@abopr.de
Internet: www.abopr.de

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